Lubricant emulsion containing a vinylmaleic acid thioester or thioether-ester-polymer salt as an emulsifying agent



United States Patent LUBRICANT EMULSION CONTAINING A VINYL- MALEIC ACID THIOESTER 0R THIOETHER- ESTER-POLYMER SALT AS AN EMULSIFYING AGENT Robert R. Chambers, Homewood, Henry V. Isaacson, Oak Forest, and David W. Young, Homewood, Ill., assignors to Sinclair Research, Ine., New York, N.Y., a corporation of Delaware No Drawing. Filed Jan. 4, 1967, Ser. No. 607,150

Int. Cl. Cm 1/32, 1/28 US. Cl. 25234.7 Claims ABSTRACT OF THE DISCLOSURE A vinyl monomer (e.g., styrene)-maleic anhydride polymer is esterified with a thioalcohol or a hydroxythioether. The product is rendered water-soluble by formation of amine, ammonium or alkali metal salt thereof, and the water-soluble salt is used as an emulsifying aid in oil-water emulsions, e.g., mineral oil-based cutting fluids.

The present invention relates to thioalcohol-esterified and hydroxythioether-esterified vinyl monomer-maleic anhydride polymers, to the ammonium, amine and alkali metal salts of such polymers, and to aqueous solutions of the polymer salts. It has now been found that vinyl monomer-maleic anhydride polymers will react with thioalcohols and hydroxy-thioethers to yield thioester and thioetherester derivatives, respectively, of the polymers, which derivatives, in their water-soluble salt forms, are especially useful in cutting oil formulations. Also, certain metal salts of the sulfur-containing esters, e.g., tin salts, have been found to exhibit stabilizing effects in, for instance, polyvinyl chloride compositions, e.g., PVC plastiso s.

The esterified polymers of the present invention can be prepared by esterifying the vinyl monomer-maleic anhydride polymer with a compound having the general formula:

wherein R is a monovalent hydrocarbon radical of about 1 to 20, preferably about 1 to 12, carbon atoms and R' is a monovalent radical selected from the group consisting of hydrogen and alkylols of about 1 to 24, preferably about 1 to 12, carbon atoms. Thus, suitable esterifying compounds are thioalcohols, known also as thiols and mercaptans, and hydroxythioethers, known also as thioetheralcohols. Preferably, R is alkyl. Illustrative esterifying compounds include, for example, methyl mercaptan, ethyl mercaptan, isooctyl mercaptan, ethylthioethanol, etc.

The reaction between the polymer and the esterifying compound takes place at the dicarboxylic anhydride sites of the polymer to form thioester or thioetherester linkages. Thus, the reaction of one mole of thioalcohol with sufficient vinyl monomer-maleic anhydride polymer to provide one mole of maleic anhydride units would yield a polymeric product having the following half-thioester of maleic acid units:

The percent, or extent of esterification of the polymer is a factor in determining the utility of the sulfur-containing, esterified polymers of the invention. By percent esterification is meant the overall percentage of total 3,472,772 Patented Oct. 14, 1969 potential carboxyl groups on the polymer chains that are in the form of the thioester group, i.e.,

o H -OS-R or in the form of the thioetherester group, i.e.,

-(J-RSR R representing the radical defined above and R" representing the divalent residue of the alkylol radical of a hydroxythioether. Potential carboxyl groups include carboxyl groups as such and groups capable of yielding the carboxyl group by hydrolysis and having the formula:

0 JLOX where X is hydrogen, hydrocarbyl, metal or carbon (e.g., as in the case of the anhydride). Thus, for instance, where 25% of the total potential carboxyl groups of the vinyl monomer-maleic anhydride polymer are esterified (25% esterification), the product is a polymer having 50% esterification based on half-esterification. The higher the percentage of esterification, the lower the solubility of the polymer in aqueous, alkaline media and the greater the organic solvent, e.g., hydrocarbon, solubility.

The present invention contemplates polymers which are esterified with the above sulfur-containing compounds in the range of about 5 to 100, preferably about 25 to percent. Where it is desired to render the esterified polymer water-soluble, the percent esterification is also important from the standpoint of leaving enough unreacted carboxyl groups to permit sufiicient amine, alkali metal or ammonium salt formation. Further, it may be desired to allow suflicient carboxyl groups to remain free for subsequent cross-linking reactions.

The esterification reaction can be conducted by known methods. Often, temperatures of about 50 C. to 200 C., preferably about to C., can be employed. The reaction may be conducted in bulk or in the presence of suitable solvents such as, for example, xylene, toluene, or an excess of the esterifying sulfur-containing compound. The reaction proceeds without the additional presence of catalyst; however, such may be employed, if desired, and as suitable catalysts may be mentioned lithium acetate and sodium methoxide. Reaction time will vary according to reactant proportions, the presence or absence of catalysts and diluents, temperature, pressure, etc. The main consideration as regards reaction time, however, is the extent of esterification sought.

The esterified polymers of the present invention are rendered water-soluble by conversion of unreacted carboxyl groups of the coplymer to their amine, alkali metal or ammonium salt forms. As suitable amines may be mentioned the water-soluble amines, for example, methyl amine, triethanolamine, etc. Preparation of the salt can be by known methods such as by the addition of the thioesterified or thioetheresterified polymer to a hot aqueous solution of ammonium hydroxide.

The polymer with which the sulfur-containing compounds are reacted to form the thioesters or thioetheresters of the present invention is a polymer of maleic anhydride and a polymerizable monovinyl compound of 2 to about 12 carbon atoms, these components being present in the polymer in a molar ratio of vinyl monomer to maleic anhydride of about 1 to 4:1, preferably about 1 to 3:1. Suitable vinyl compounds include, for instance, ethylene, propylene, isobutylene, butylene, pentylene, hexylene, heptylene, octylene, nonylene, decylene, dodecylene, methyl vinyl ether, ethyl vinyl ether, butyl vinyl ether, styrene, vinyl toluene, and the like. The preferred vinyl monomer is styrene. If desired, maleic acid can be used instead of maleic anhydride in formation of the polymer, and the use of the term maleic anhydride herein and in the claims is intended to include maleic acid.

The polymer contains repeating vinyl monomer and maleic anhydride units and, in unesterified form, may have an average molecular weight of about 400 to 18,000, preferably about 600 to 15,000. The melting point may generally range from about 80 to 300 C., and a by weight solution of the polymer in acetone will generally exhibit a viscosity at 30 C. of up to about 2 centistokes, preferably less than about 1 centistoke.

Preparation of the vinyl monomer-maleic anhydride polymer can be by known methods. A preferred method is by solution polymerization where the monomers are polymerized in a suitable solvent employing as a polymerization catalyst a free-radical catalyst, such as a peroxide, preferably benzoyl peroxide, dicumyl peroxide, or an alkyl peroxy dicarbonate, at a temperature of about 75 to 300 C. or more. Suitable solvents include the aromatic hydrocarbon solvents, such as cumene, p-cymene, xylene, toluene, etc. Other suitable solvents are the ketones, such as methylethylketone. The preferred manner of carrying out the polymerization is by what is known as incremental feed addition. By this method the monomers and catalyst are first dissolved in a portion of the solvent in which the polymerization is to be conducted and the resulting solution fed in increments into a reactor containing solvent heated to reaction temperature, usually the refiux temperature of the mixture.

When an aromatic solvent is employed as the solvent for the polymerization, the formation of the copolymer causes a heterogeneous system, the polymer layer being the heavier layer and recoverable by merely decanting the upper aromatic solvent layer and drying. On the other hand, when a ketone is the solvent, the formed copolymer is usually soluble in the solvent media so that recovery of the product necessitates a solvent-stripping operation.

Typical properties of, for example, styrene-maleic anhydride resins from which the thioesters or thioetheresters of the present invention can be prepared are as follows:

The water-soluble salts of the thioesterified or thioetheresterified polymers of the present invention are useful as emulsifying aids in hydrocarbon oil-based emulsifiable oils, which oils find utility, for example, in cutting, spraying and rust-preventing applications. The oils used as the base component are preferably mineral oils of lubricating viscosity and include, for instance, petroleum lubricating oils such as refined coastal and Mid-Continent oils. Refining may be by acid-treatment, solvent extraction, hydrogenation or other procedures. Often the oils exhibit a viscosity from about 50 to 1200 SUS at 100 F., most preferably about 50 to 150 SUS at 100 F.

The water-soluble salt of the sulfur-containing esters of the present invention can be included in the emulsifiable oils in minor amounts, e.g., about 1 to 50, preferably at least about 5, percent by weight of the base hydrocarbon oil. In addition to the base oil and the ester derivative, the emulsifiable oil will often include one or more other additives such as rust and foam inhibitors, bactericides, etc. Water may initially be added in small amounts to form a concentrate which may be further diluted at time of use in a ratio of, say, up to about 200, preferably about 2 to parts of water per one part of the emulsifiable oil composition.

The following examples, which are to be considered illustrative only and not limiting, describe the preparation of the thioesterified and thioetheresterified polymers of the present invention.

EXAMPLE I Into a 500 ml. resin kettle was added a mixture of the styrene-maleic anhydride polymer grams) identified in Table I as Resin A and 2-methyl-2-heptanethiol, known synonymously as tert-octylmercaptan (55 grams). The kettle was immersed in an oil bath at 200 C. and kept there for five hours with stirring; the resin thus treated was then precipitated in acetone and dried. The resulting product was an approximately 50% half-thioester of the styrene-maleic anhydride polymer. The prodduct analyzed: 71.46 wt. percent C, 6.30 wt. percent H, and 3.05 wt. percent S.

The ammonium salt was prepared by addition of the thioester to a warm (50 C.) solution of ammonium hydroxide. The ammonium salt of the thioester was then precipitated in acetone and dried.

The thioester salt was tested as an emulsion aid in cutting oils; the results are given in Table II to follow.

EXAMPLE II TABLE II.-TAPPING TEST COMPARISONS Sample No 7009 7002 7003 Cutting oil base, wt. percent--- 12. 5 12. 5 Water, wt. percent 87. 5

Aqueous soln. (1 wt. percent) of ammonium salt of Ex. I, wt. percent Aqueous soln. (1 wt. percent) of ammonium salt of Ex. II, wt. percen 87. 5

Metal Tap No. Tapping torque, inch pounds AISI-1042-Exp. 8695 6 122 129 122 AISI-8620Heat 51219- 9 122 114 118 AISI-9310-Heat 69712. 8 140 134 138 303 Stainless-Exp. 8695 7 166 167 Ingredients:

Petroleum sulionate- Oleyl oleate Diethylene glycol. Mineral Lube oil- 37 "34-13 NO spiral point plug tap 55 ROM, 0.440 hole (62% thread) Fosdick setup.

The data presented in the above table indicate the value of the ammonium salts of the thioesterified and hydroxythioether-esterified polymers of the present invention as emulsion aids in cutting oil compositions used to cool and lubricate metal working operations on No. 8620 and No. 9310 steel.

It is claimed:

1. An aqueous emulsion comprising:

(a) a base mineral oil of lubricating viscosity,

(b) about 1 to 50 percent, by weight of the base mineral oil, of a water-soluble salt of an esterified vinyl monomer-maleic anhydride polymer having a molar ratio of vinyl monomer to maleic anhydride of about 1 to 4:1 and an unesterified molecular weight of about 400 to 18,000, said vinyl monomer having 2 to about 12 carbon atoms, wherein about 25 to 75 percent of the potential carboxyl groups in said polymer are esterified with a compound corresponding to the formula:

wherein R is a monovalent hydrocarbon radical of l to about 20 carbon atoms and R is a monovalent radical selected from the group consisting of hydrogen and alkylols of 1 to about 24 carbon atoms, said water-soluble salt being selected from the group consisting of amine, alkali metal and ammonium salts of the esterified polymer, and

(c) about 2 to 200 parts of water per each combined part of said (a) and (b).

2. The aqueous emulsion of claim 1 wherein the vinyl monomer is styrene.

3. The aqueous emulsion of claim 2 wherein R is alkyl.

4. The aqueous emulsion of claim 3 wherein the esterifying compound is 2-methyl-2-heptanethiol.

5. The aqueous emulsion of claim 3 wherein the esterifying compound is ethylthioethanol.

6. The aqueous emulsion of claim 3 wherein the molar ratio of styrene to maleic anhydride is approximately 1:1.

7. An emulsifiable oil composition comprising:

(a) a base mineral oil of lubricating viscosity and (b) about 1 to 50 percent, by weight of the base mineral oil, of a water-soluble salt of an esterified styrene-maleic anhydride polymer having a molar ratio of styrene to maleic anhydride of about 1 to 4:1 and an unesterified molecular weight of about 400 to 18,000, wherein about 25 to 75 percent of the potential carboXyl groups in said polymer are esterified with a compound corresponding to the formula:

wherein R is a monovalent hydrocarbon radical of l to about 20 carbon atoms and R is a monovalent radical selected from the group consisting of hydrogen and alkylols of 1 to about 24 carbon atoms, said water-soluble salt being selected from the group consisting of amine, alkali metal and ammonium salts of the esterified polymer. 8. An emulsifiable oil composition of claim 7 wherein R is alkyl.

9. An emulsifiable oil composition of claim 8 wherein the esterifying compound is Z-methyl-Z-heptanethiol.

10. An emulsifiable oil composition of claim 8 wherein the esterifying compound is ethylthioethanol.

11. An emulsifiable oil composition of claim 8 wherein the molar ratio of styrene to maleic anhydride is approximately 1:1.

12. An emulsifiable oil composition comprising: (a) a base mineral oil of lubricating viscosity and (b) about 1 to percent, by weight of the base mineral oil, of a water-soluble salt of an esterified vinyl monomer-maleic anhydride polymer having a molar ratio of vinyl monomer to maleic anhydride of about 1 to 4:1 and an unesterified molecular weight of about 400 to 18,000, said vinyl monomer having 2 to about 12 carbon atoms, wherein about 25 to percent of the potential carboxyl groups in said polymer are esterified with a compound corresponding to the formula:

wherein R is a monovalent hydrocarbon radical of 1 to about 20 carbon atoms and R is an alkylol of 1 to about 24 carbon atoms, said water-soluble salt being selected from the group consisting of amine, alkali metal and ammonium salts of the esterified polymer.

13. An emulsifiable oil composition of claim 12 wherein the vinyl monomer is styrene.

14. An emulsifiable oil composition of claim 13 wherein R is alkyl.

15. An emulsifiable oil composition of claim 14 wherein the molar ratio of styrene to maleic anhydride is approximately 1:1.

References Cited UNITED STATES PATENTS 2,615,845 10/1952 Lippincott et al. 25256 2,694,685 11/1954 Bartlett 25256 2,892,786 6/1959 Stewart et al. 252-56 X 2,992,987 7/1961 Fields 25256 3,206,400 9/1965 Flowers 25249.5 3,322,713 5/1967 Williams 260-78.5 X

DANIEL E. WYMAN, Primary Examiner W. CANNON, Assistant Examiner US. Cl. X.R. 

